Modular fixture plate system for positioning a workpiece during a manufacturing and/or inspection process

ABSTRACT

A modular fixture plate system comprising: 
     at least one interlocking fixture plate comprising at least one of a male end and a female end, wherein the male end comprises at least one male projection and the female end comprises at least one female recess; and 
     a docking plate comprising at least one of at least one male projection and at least one female recess; 
     wherein at least one male projection or female recess of the at least one interlocking fixture plate is interlocked with a mating one of the at least one male projection or the at least one female recess of the docking plate.

REFERENCE TO PENDING PRIOR PATENT APPLICATIONS

This patent application claims benefit of:

(i) pending prior U.S. Provisional Patent Application Ser. No.61/771,575, filed Mar. 1, 2013 by Steven E. Phillips for LOC-N-LOAD™MODULAR FIXTURE PLATE SYSTEM FOR INSPECTION MACHINES (Attorney's DocketNo. PHIL-5 PROV); and

(ii) pending prior U.S. Provisional Patent Application Ser. No.61/825,846, filed May 21, 2013 by Steven E. Phillips for LOC-N-LOAD™MODULAR FIXTURE PLATE SYSTEM FOR REPEATABLE, LIGHT DUTY WORK (Attorney'sDocket No. PHIL-6 PROV).

The two (2) above-identified patent applications are hereby incorporatedherein by reference.

FIELD OF THE INVENTION

This invention relates to methods and apparatus for manufacturing and/orinspection processes, and more particularly to methods and apparatus forpositioning a workpiece during a manufacturing and/or inspectionprocess.

BACKGROUND OF THE INVENTION

A number of manufacturing and/or inspection processes exist that requireaccurate, repeatable positioning of a workpiece. By way of example butnot limitation, processes such as quality inspection, laser marking andetching, fiber laser and laser machining, dot peen marking, pad printingand routing all require accurate, repeatable positioning of a workpiece.

During a manufacturing process, a workpiece is typically held in aspecific position while work is performed on the workpiece, and then theworkpiece is “swapped out” for a new workpiece which is to be worked on.This new workpiece generally needs to be placed in the same, repeatableposition as the preceding workpiece in order for the work process to beperformed accurately.

In quality inspection processes, metal and/or plastic fixture plates aretypically affixed to inspection machines to facilitate the qualityinspection of previously-manufactured workpieces (i.e., to test thecorrectness of the manufactured workpieces). These fixture platesgenerally comprise a pattern of threaded holes formed therein whichaccept workpiece-holding elements such as screws, clamps, magnets,hold-downs, etc. In the quality inspection process, thepreviously-manufactured workpiece is placed on these metal and/orplastic fixture plates, held down with the workpiece-holding elementsand then the previously-manufactured workpiece is measured forcorrectness. Once the workpiece on the fixture plate has been inspected,the workpiece is replaced by another workpiece which is to be inspectedusing the same inspection set-up, fixture plates, etc.

The aforementioned fixture plates are currently a one-piece design andare made to fit the workbed area of a particular inspection machine. Asa result, different sizes of fixture plates must be provided fordifferent inspection machines, thereby presenting an inventory issue orrequiring long lead-times to custom manufacture fixture plates.

In addition to the foregoing, workpieces vary in size and, in manycases, a workpiece may be relatively small and take up only a smallfraction of the complete surface area of the fixture plate provided fora given inspection machine. In this case, the remainder of the fixtureplate is essentially unused during the quality inspection process.

In the same way that a quality inspection process applies very littleforce on a workpiece that is being inspected, the processes of lasermarking and etching, fiber laser and laser machining, dot peen marking,pad printing, and routing also tend to apply little or no force to theworkpiece.

In a manner similar to a quality inspection machine, these “light duty”manufacturing machines generally have a work surface on which theworkpiece is supported during processing. By way of example but notlimitation, the laser etching of part numbers on workpieces is a verycommon practice. Logo's, bar codes and/or other markings are alsoroutinely added to workpieces.

For these reasons, it would be advantageous to provide a new andimproved fixture plate system for positioning a workpiece during aquality inspection process and/or “light duty” manufacturing process,wherein the improved fixture plate system uses a modular approach toallow for the creation of simple but effective fixture assemblies thatcan provide fast, easy and repeatable setups for a specific productionrun.

SUMMARY OF THE INVENTION

The present invention provides a new and improved fixture plate systemfor positioning a workpiece during a quality inspection process and/or“light duty” manufacturing process, wherein the improved fixture platesystem uses a modular approach to allow for the creation of simple buteffective fixture assemblies that can provide fast, easy and repeatablesetups for a specific production run.

In one preferred form of the invention, there is provided a modularfixture plate system comprising:

at least one interlocking fixture plate comprising at least one of amale end and a female end, wherein the male end comprises at least onemale projection and the female end comprises at least one female recess;and

a docking plate comprising at least one of at least one male projectionand at least one female recess;

wherein at least one male projection or female recess of the at leastone interlocking fixture plate is interlocked with a mating one of theat least one male projection or the at least one female recess of thedocking plate.

In another preferred form of the invention, there is provided aninterlocking fixture plate comprising:

a surface for receiving a workpiece;

a male end comprising at least one male projection; and

a female end comprising at least one female recess.

In another preferred form of the invention, there is provided a methodfor positioning a workpiece during a manufacturing and/or inspectionprocess, the method comprising:

providing a modular fixture plate system comprising:

-   -   at least one interlocking fixture plate comprising at least one        of a male end and a female end, wherein the male end comprises        at least one male projection and the female end comprises at        least one female recess; and    -   a docking plate comprising at least one of at least one male        projection and at least one female recess;

interlocking at least one male projection or female recess of the atleast one interlocking fixture plate with a mating one of the at leastone male projection or the at least one female recess of the dockingplate so as to stabilize the at least one interlocking fixture platerelative to the docking plate; and

positioning a workpiece on the at least one interlocking fixture plate.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects and features of the present invention will bemore fully disclosed or rendered obvious by the following detaileddescription of the preferred embodiments of the invention, which is tobe considered together with the accompanying drawings wherein likenumbers refer to like parts, and further wherein:

FIGS. 1 and 2 are schematic views showing a novel modular fixture platesystem formed in accordance with the present invention;

FIGS. 3-6 are schematic views showing various interlocking fixtureplates formed in accordance with the present invention;

FIGS. 8 and 9 are schematic views showing various docking plates formedin accordance with the present invention;

FIG. 9 is a schematic view showing another novel modular fixture platesystem formed in accordance with the present invention;

FIGS. 10-13 are schematic views showing how magnets may be mounted tointerlocking fixture plates;

FIGS. 14-16 are schematic views showing how magnets may be mounted to adocking plate;

FIG. 17 is a schematic view showing how the novel modular fixture platesystem may include a base plate;

FIGS. 18-20 show how the male projections and female recesses of theinterlocking fixture plates and the docking plate may be formed with adovetail configuration;

FIG. 21 is a schematic view showing how the interface of a maleprojection and a female recess may be given a unique “Location” or “LOC”number;

FIGS. 22-27 are schematic views showing how the novel modular fixtureplate system may include a removable qualifying ball plate;

FIGS. 28-31 are schematic views showing how the various elements of thenovel modular fixture plate system may be formed out of molded plastic;

FIGS. 32 and 33 are schematic views showing how an interlocking fixtureplate may be formed out of a conventional fixture plate and an “add on”male projection.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention provides a new and improved fixture plate systemfor positioning a workpiece during a quality inspection process and/or“light duty” manufacturing process, wherein the improved fixture platesystem uses a modular approach to allow for the creation of simple buteffective fixture assemblies that can provide fast, easy and repeatablesetups for a specific production run.

Among other things, the present invention comprises a new modularfixture plate system which allows for, and encourages, leanmanufacturing principles for, but not limited to, quality inspectionprocesses and “light duty” manufacturing processes such as laser markingand etching, fiber laser and laser machining, dot peen marking, padprinting and routing processes. More particularly, the present inventioncomprises a modular fixture plate system which comprises a plurality ofinterlocking plates which are selected, and then assembled together, soas to form a complete fixture plate, or which can be used individuallyso as to allow a portion of the workbed area of the inspection ormanufacturing machine to be exposed, with the specific interlockingplates used being selected according to the size of the workpiece whichis to be held, so that only those interlocking plates are used which arerequired to hold the workpiece of interest. Or, in another aspect of thepresent invention, a workpiece may be set up and programmed forinspection or working on a single interlocking plate, which can then beeasily positioned on the inspection or manufacturing machine, theworkpiece inspected or worked, then the workpiece and interlocking platemay be removed as a unit from the workbed of the inspection ormanufacturing machine and thereafter be replaced by another workpieceand interlocking plate. The new modular fixture plate system of thepresent invention encourages inspectors and machine operators to employlean manufacturing principles in the inspection and “light duty”manufacturing processes, using the minimum resources required, andenhances the value and investment of the inspection and “light duty”manufacturing equipment.

Looking first at FIGS. 1 and 2, there is shown a new modular fixtureplate system 5 formed in accordance with the present invention. Modularplate system 5 generally comprises one or more interlocking fixtureplates 10 which are intended to be positioned on the workbed 12 of aninspection or “light duty” manufacturing machine. Each interlockingfixture plate 10 comprises a male end 15 and a female end 20, whereinmale end 15 comprises at least one male projection 25 and female end 20comprises at least one female recess 30. Preferably interlocking fixtureplates 10 comprise a plurality of threaded holes 32, preferably disposedin a regular pattern, for accepting workpiece-holding elements wellknown in the art, e.g., screws, clamps, magnets, hold-downs, etc. Asseen in FIGS. 1-6 interlocking fixture plates 10 can be formed in avariety of configurations, each with one or more male projections 25 andone or more female recesses 30.

Modular plate system 5 also comprises a docking plate 35 (FIGS. 1, 2, 7and 8) which is intended to be affixed to the workbed of the inspectionor “light duty” manufacturing machine, e.g., using an adhesive in whichcase the docking plate may comprise a solid structure (FIGS. 1 and 2) orusing bolts which extend through counterbored slots 40 formed in dockingplate 35 (FIGS. 7 and 8). Docking plate 35 comprises a plurality offemale recesses 30 (FIGS. 1, 2, 7 and 8), also sometimes referred toherein as “Locations” or “LOCs”, which receive male projections 25 ofone or more interlocking fixture plates 10 or, alternatively, dockingplate 35 comprises a plurality of male projections 25 for projectinginto female recesses 30 of one or more interlocking fixture plates 10(FIG. 9).

Docking plate 35 and the various interlocking fixture plates 10 aredesigned to fit tightly together in an interlocked manner, with a maleprojection 25 of one element being received in a female recess 30 ofanother element. By way of example but not limitation, where dockingplate 35 comprises a plurality of female recesses 30 (FIGS. 1, 2 and 9),a plurality of interlocking fixture plates 10 may be interlocked withdocking plate 35, and also with one another, by projecting the maleprojections 25 of some of the interlocking fixture plates 10 into thefemale recesses 30 of docking plate 35 and by projecting the maleprojections 25 of others of the interlocking fixture plates 10 into thefemale recesses 30 of the interlocking fixture plates 10 interlockedwith docking plate 35. By way of further example but not limitation, adocking plate 35 having a plurality of male projections 25 may beinterlocked with interlocking fixture plates 10 by projecting the maleprojections of docking plate 35 into the female recesses of interlockingfixture plates 10 (FIG. 9).

Thus it will be seen that with fixture plate system 5, a plurality ofinterlocking fixture plates 10 can be interlocked with one another, andwith docking plate 35, so as to cover some or all of the workbed of aninspection or manufacturing machine, and a large workpiece can span anumber of interlocked fixture plates 10. In other words, with thepresent invention, interlocking fixture plates 10 fit together (e.g., inthe manner of a jigsaw puzzle) to collectively create the desiredoverall size for the fixture plate.

Preferably docking plate 35 and the various interlocking fixture plates10 are further secured to one another by magnets 45 which are disposedadjacent to male projections 25 of interlocking fixture plates 10 (FIGS.10 and 11) and adjacent to female recesses 30 of interlocking fixtureplates 10 (FIGS. 12 and 13), and by magnets 45 which are disposedadjacent to female recesses 30 of docking plate 35 (FIG. 14) andadjacent to male projections 25 of docking plate 35 (FIGS. 15 and 16).Preferably magnets 45 are inset into docking plate 35 and interlockingfixture plates 10 so that the magnets of one plate mate with the magnetsof an adjoining plate when a male projection 25 is received in a femalerecess 30. Using magnets 45 to secure docking plate 35 and interlockingfixture plates 10 to one another allow interlocking fixture plates 10 tobe easily released from one another, and from docking plate 35, by handand without the use of tools, whereby to enable interlocking fixtureplates 10 to be quickly and easily swapped out as needed.

Alternatively, if desired, other means (e.g., a spring plunger setscrew) may be used to secure docking plate 35 and the variousinterlocking fixture plates 10 to one another.

Or, if desired, two or more docking plates 35 may be used in opposingarrangement (FIG. 9) so as to lock the interlocking fixture plates 10 inposition.

Since many “light duty” manufacturing machines (e.g., laser engravingmachines and the like) are not necessarily sold with a workbed surface,modular fixture plate system 5 may also comprise a base plate 50 (FIG.17) on which the remainder of the system (e.g., docking plate 35 and oneor more interlocking fixture plates 10) may be mounted.

For some “light duty” manufacturing machines (e.g., workpiece markingmachines), one preferred form of the invention may provide aninterlocking fixture plate 10 which interlocks with only docking plate35 (FIG. 17), with the opposite end of interlocking fixture plate 10being straight and with or without a handle or finger grip for easierremoval of interlocking fixture plate 10.

Alternatively, modular plate system 5 may provide docking plates 35 onall sides of interlocking fixture plates 10 so that the interlockingfixture plates 10 are interlocked, much like the pieces of a puzzle. Inthis case, the aforementioned magnets 45 can be omitted.

In still another form of the present invention, male projections 25 andfemale recesses 30 may utilize a dovetail configuration (FIGS. 18-20).

It should be appreciated that each of the interlocks of an interlockingfixture plate 10 with a docking plate 35 (i.e., a male projection 25fitting into a female recess 30) can be assigned a “Location” or “LOC”number (see FIGS. 2, 7, 9, 20 and 21). Inspection and manufacturingprograms can be written and assigned to a specific “Location” or “LOC”number, i.e., to a specific location of an interlocking fixture plate 10relative to docking plate 35. Programming inspection and manufacturingsetups based on the interlocking fixture plate location or assignmentallows for faster repeat setups and allows for more than one setup permachine (i.e., it permits work to be effected at LOC1, LOC2, LOC3,etc.), thereby speeding up the inspection and manufacturing processes.

The hole pattern (i.e., the pattern of the holes 32 provided ininterlocking fixture plates 10) is preferably consistent and seamlessacross all interlocking fixture plates 10 (FIGS. 1 and 2). By way ofexample but not limitation, a ¼-20 or M6 threaded hole pattern with 1inch spacing is shown in FIGS. 1 and 2. The described thread and holepattern is typical of the industry, however, it can vary widely inthread size and hole spacing without departing from the scope of thepresent invention. In one form of the present invention, interlockingfixture plates 10 can be created as “blanks” (i.e., without holes 32) sothat the end user can then add the holes 32 in the sizes and/or patternsdesired.

Another unique feature of modular fixture plate system 5 is theprovision of a removable qualifying ball plate 55 which may be used forquality inspection, e.g., FIGS. 22 and 23 show one possibleconfiguration for qualifying ball plate 55 and FIGS. 24 and 25 showanother possible configuration for qualifying ball plate 55. Theremovable qualifying ball plate 55 preferably comprises a rounded end 60on one end and a male projection 25 on its other end, where maleprojection 25 allows removable qualifying ball plate 55 to be secured toanother element of modular fixture plate system 5 (i.e., an interlockingfixture plate 10 or a docking plate 35).

Alternatively, removable qualifying ball plate 55 may comprise a roundedend 60 on one end and a female recess 30 on its other end, where femalerecess 30 allows removable qualifying ball plate 55 to be secured toanother element of modular fixture plate system 5 (i.e., an interlockingfixture plate 10 or a docking plate 35). The removable qualifying ballplate 55 is a precise tool which carries a qualifying ball 62 (FIGS. 26and 27) which the probe of an inspection machine touches in order toregister the inspection machine. By way of example but not limitation,qualifying ball 62 can be attached to removable qualifying ball plate 55(e.g., to rounded end 60 of removable qualifying ball plate 55) suchthat qualifying ball 62 is upstanding from the plane of removablequalifying ball plate 55. This removable qualifying ball plate 55 willnormally stay on the inspection machine's work surface whilemanufactured workpieces are inspected. This removable qualifying ballplate 55 is designed to accept the qualifying ball 62 (or the inspectionmachine test bar), provide an accurate surface for indicating withrespect to the inspection machine probe, and can be moved out of the wayquickly and easily when not in use. The surface area and work envelopeof the inspection machine is completely free from obstructions and thenhas more useable space.

The suggested material of all interlocking fixture plates 10 is halfinch thick aluminum plate, however, the interlocking fixture plates canbe manufactured in a variety of other metals or plastics (see FIGS.28-31) and can vary in thickness, overall size and geometry, withthreaded, straight or tapered holes 32, with and without a subplate. Thesize of the interlocking fixture plates 10 is chosen based on the sizeand number of workpieces, and for the size of the machine work area.

FIGS. 32 and 33 show another possible construction for interlockingfixture plates 10, wherein male projection 25 is manufactured separatelyfrom the remainder of interlocking fixture plate 10, and is added duringthe manufacturing process. This approach has the advantage that maleprojection 25 can be added to an existing fixture plate so as to make itusable with the present invention.

Benefits of the New Fixture Plate System

Some of the benefits of the new modular fixture plate system 5 are asfollows:

-   -   The continuous threaded hole pattern from one interlocking        fixture plate to another creates a seamless surface when the        interlocking fixture plates 10 are assembled together.    -   The interlocking fixture plates 10 can be swapped out quickly        while maintaining an accurate repeatable location.    -   The interlocking fixture plates 10 can be ordered as blanks        (i.e., without holes) and then customized by the end user for an        even lower cost solution.    -   Standard-sized interlocking fixture plates 10 can be ordered        “off-the-shelf”, and then configured quickly according to the        end user's particular work needs.    -   Initial costs are lower since the end user need only order the        docking plate 35 and those interlocking fixture plates 10 needed        for a particular job, and the end user can then add additional        interlocking fixture plates 10 anytime thereafter as needed.    -   No tools are necessary to assembly/disassemble particular setups        of the modular fixture plate system (after docking plate 35 has        been secured to the workbed of a machine).    -   Docking plate 35 can be mounted to the workbed of the inspection        or manufacturing machine using either an adhesive (e.g.,        double-sided tape) or bolts, etc.    -   Interlocking fixture plates 10 are provided in various sizes so        as to collectively make up a uniform, larger fixture plate        assembly.    -   Multiple workpieces can be fixed to an interlocking fixture        plate 10 and then that interlocking fixture plate 10 can be        “swapped out” for inspecting and/or working all of the        workpieces at the same time; the interlocking fixture plates 10        can be stored when the job is complete.    -   Interlocking fixture plates 10 can be provided with dedicated        tooling for jobs to reduce setup times and machine operators can        pre-set workpieces on interlocking fixture plates 10 so that the        workpieces are ready to be inspected and/or worked, thereby        improving the production process.    -   Multiple interlocking fixture plates 10 can be provided to        accommodate larger workpieces.    -   It is not necessary to cover the entire workbed with        interlocking fixture plates 10.    -   The ends of the interlocking fixture plates 10 interlock with        one another, and may be kept in place using magnets (e.g.,        strong rare earth magnets) for a strong locking action.    -   Docking plate 35 seats against a far side of a machine's workbed        (i.e., out of the way of the work envelope/travel of the probe,        laser, or other tools) whereby to provide maximum use of the        machine's workbed.    -   Docking plate 35 can be quickly and easily secured to the        workbed by using double-sided tape or by using counterbored        slots 40 to bolt the docking plate to the machine workbed.    -   Interlocking fixture plates 10 can be provided in various sizes,        whereby to fit any size machine workbed or to accommodate any        size workpiece requiring inspection, marking, or light        machining.    -   Designed to reflect Lean Manufacturing principles.    -   Interlocking fixture plates 10 can be quickly “swapped out” for        inspection, thereby reducing the chance of damaging probes.    -   Existing interlocking fixture plates 10 can be retroactively        modified for use with the system using separately-manufactured        male projections 25.    -   A special ball plate 55 can be provided for quality inspection        (i.e., locating the ball). The ball can be inspected and then        moved out of the way quickly for an unobstructed workbed.    -   A simple and inexpensive base plate 50 can be provided to mount        the fixture plate system 5 to a machine.    -   Plastic injection molding can be used to manufacture low-cost        interlocking fixture plates 10 for the marking industry.

Modifications of the Preferred Embodiments

It should be understood that many additional changes in the details,materials, steps and arrangements of parts, which have been hereindescribed and illustrated in order to explain the nature of the presentinvention, may be made by those skilled in the art while still remainingwithin the principles and scope of the invention.

What is claimed is:
 1. A modular fixture plate system comprising: atleast one interlocking fixture plate comprising at least one of a maleend and a female end, wherein the male end comprises at least one maleprojection and the female end comprises at least one female recess; anda docking plate comprising at least one of at least one male projectionand at least one female recess; wherein at least one male projection orfemale recess of the at least one interlocking fixture plate isinterlocked with a mating one of the at least one male projection or theat least one female recess of the docking plate.
 2. A modular fixtureplate system according to claim 1 wherein the at least one interlockingfixture plate comprises a male end and a female end.
 3. A modularfixture plate system according to claim 1 wherein the male end comprisesa plurality of male projections.
 4. A modular fixture plate systemaccording to claim 1 wherein the female end comprises a plurality offemale recesses.
 5. A modular fixture plate system according to claim 1comprising a plurality of interlocking fixture plates.
 6. A modularfixture plate system according to claim 1 wherein the docking platecomprises at least one male projection.
 7. A modular fixture platesystem according to claim 1 wherein the docking plate comprises aplurality of male projections.
 8. A modular fixture plate systemaccording to claim 1 wherein the docking plate comprises at least onefemale recess.
 9. A modular fixture plate system according to claim 1wherein the docking plate comprises a plurality of female recesses. 10.A modular fixture plate system according to claim 1 comprising aplurality of docking plates.
 11. A modular fixture plate systemaccording to claim 1 wherein the at least one interlocking fixture platecomprises at least one threaded hole formed therein.
 12. A modularfixture plate system according to claim 11 wherein the least oneinterlocking fixture plate comprises a plurality of threaded holesformed therein.
 13. A modular fixture plate system according to claim 12wherein the plurality of threaded holes are arranged in a regularpattern.
 14. A modular fixture plate system according to claim 1 furthercomprising at least one magnet disposed on at least one of the least oneinterlocking fixture plate and the docking plate.
 15. A modular fixtureplate system according to claim 14 further comprising at least onemagnet disposed on the least one interlocking fixture plate and at leastone magnet disposed on the docking plate.
 16. A modular fixture platesystem according to claim 1 further comprising a base plate forattachment to a machine, wherein the base plate is configured to receivethe least one interlocking fixture plate and the docking plate.
 17. Amodular fixture plate system according to claim 1 wherein the at leastone male projection and the at least one female recess are formed in adovetail configuration.
 18. An interlocking fixture plate comprising: asurface for receiving a workpiece; a male end comprising at least onemale projection; and a female end comprising at least one female recess.19. A method for positioning a workpiece during a manufacturing and/orinspection process, the method comprising: providing a modular fixtureplate system comprising: at least one interlocking fixture platecomprising at least one of a male end and a female end, wherein the maleend comprises at least one male projection and the female end comprisesat least one female recess; and a docking plate comprising at least oneof at least one male projection and at least one female recess;interlocking at least one male projection or female recess of the atleast one interlocking fixture plate with a mating one of the at leastone male projection or the at least one female recess of the dockingplate so as to stabilize the at least one interlocking fixture platerelative to the docking plate; and positioning a workpiece on the atleast one interlocking fixture plate.